3D Multiphysics Simulation of Jet Electrochemical Machining of Intersecting Line Removals

Abstract

Jet electrochemical machining (Jet-ECM) is a non-conventional machining technology based on anodic metal dissolution. Jet-ECM utilizes a free-surface electrolyte jet to localize material removal. In this study Jet-ECM of intersecting line removals is investigated by help of experiments and simulation. The machining process is simulated with a 3D Finite Volume model considering the stratified two-phase flow of electrolyte and air. Furthermore, electrodynamics is modeled in terms of primary current distribution, and material removal is regarded transiently via geometry deformation according to Faraday’s law. The results reveal why an asymmetrical current profile occurs in Jet-ECM of intersecting line removals.